Grizzly G9859, G9861, G9860ZX User Manual 3
COPYRIGHT © MARCH, 2002 BY GRIZZLY INDUSTRIAL, INC.
WARNING: NO PORTION OF THIS MANUAL MAY BE REPRODUCED IN ANY SHAPE
OR FORM WITHOUT THE WRITTEN APPROVAL OF GRIZZLY INDUSTRIAL, INC.
PRINTED IN TAIWAN.
ULTIMATE SERIES JOINTERS
MODELS G9859 / G9860 / G9860ZX / G9861
INSTRUCTION MANUAL
WARNING
Some dust created by power sanding, sawing, grinding, drilling, and other construction activities contains
chemicals known to the State of California to cause
cancer, birth defects or other reproductive harm. Some
examples of these chemicals are:
• Lead from lead-based paints.
• Crystalline silica from bricks, cement, and other
masonry products.
• Arsenic and chromium from chemically treated
lumber.
Your risk from these exposures varies, depending on
how often you do this type of work. To reduce your
exposure to these chemicals: work in a well ventilated
area, and work with approved safety equipment, such
as those dust masks that are specially designed to filter out microscopic particles.
Ultimate Series Jointers -1-
Table Of Contents
PAGE
1. SAFETY
SAFETY INSTRUCTIONS FOR POWER TOOLS ..............................................2-3
ADDITIONAL SAFETY INSTRUCTIONS FOR JOINTERS ....................................4
2. CIRCUIT REQUIREMENTS
220V OPERATION ..................................................................................................5
CIRCUIT LOAD ........................................................................................................5
GROUNDING ..........................................................................................................6
EXTENSION CORDS ..............................................................................................6
3. INTRODUCTION
COMMENTARY........................................................................................................7
COMPARISON CHART AND TERMS ....................................................................8
UNPACKING ............................................................................................................9
PIECE INVENTORY ................................................................................................9
CLEAN UP ............................................................................................................10
SITE CONSIDERATIONS ......................................................................................10
4. ASSEMBLY
BEGINNING ASSEMBLY ......................................................................................11
FENCE ..............................................................................................................11-12
CUTTERHEAD ......................................................................................................12
PEDESTAL SWITCH..............................................................................................13
5. ADJUSTMENTS
GENERAL ..............................................................................................................14
KNIVES ............................................................................................................14-15
SPIRAL CUTTERHEAD ........................................................................................16
OUTFEED TABLE ..................................................................................................16
INFEED TABLE ......................................................................................................17
90˚ FENCE STOP ..................................................................................................17
45˚ FENCE STOP ..................................................................................................18
6. OPERATIONS
TEST RUN ............................................................................................................19
STOCK INSPECTION ..........................................................................................19
EDGE JOINTING ..................................................................................................20
BEVELING ............................................................................................................20
SURFACE PLANING ............................................................................................21
7. MAINTENANCE
GENERAL ............................................................................................................22
TABLES ................................................................................................................22
LUBRICATION ......................................................................................................22
V-BELT ..................................................................................................................22
8. CLOSURE ..................................................................................................................23
TROUBLESHOOTING GUIDE ..........................................................................................24
MACHINE DATA, PARTS BREAKDOWN AND PARTS LISTS ................................25-48
WARRANTY AND RETURNS ......................................................................................50-52
-2- Ultimate Series Jointers
Safety Instructions For Power Tools
SECTION 1: SAFETY
5. KEEP CHILDREN AND VISITORS
AWAY. All children and visitors should be
kept a safe distance from work area.
6. MAKE WORKSHOP CHILD PROOF with
padlocks, master switches, or by removing
starter keys.
7. DO NOT FORCE TOOL. It will do the job
better and safer at the rate for which it was
designed.
8. USE RIGHT TOOL. Do not force tool or
attachment to do a job for which it was not
designed.
1. KEEP GUARDS IN PLACE and in working
order.
2. REMOVE ADJUSTING KEYS AND
WRENCHES. Form habit of checking to
see that keys and adjusting wrenches are
removed from tool before turning on.
3. KEEP WORK AREA CLEAN. Cluttered
areas and benches invite accidents.
4. DO NOT USE IN DANGEROUS ENVIRONMENT. Do not use power tools in
damp or wet locations, or where any flammable or noxious fumes may exist. Keep
work area well lighted.
For Your Own Safety Read Instruction
Manual Before Operating This Equipment
Indicates an imminently hazardous situation which, if not avoided,
WILL result in death or serious injury.
Indicates a potentially hazardous situation which, if not avoided,
COULD result in death or serious injury.
Indicates a potentially hazardous situation which, if not avoided,
MAY result in minor or moderate injury. It may also be used to alert
against unsafe practices.
This symbol is used to alert the user to useful information about
proper operation of the equipment.
The purpose of safety symbols is to attract your attention to possible hazardous conditions. This
manual uses a series of symbols and signal words which are intended to convey the level of
importance of the safety messages. The progression of symbols is described below. Remember
that safety messages by themselves do not eliminate danger and are not a substitute for proper
accident prevention measures.
NOTICE
Ultimate Series Jointers -3-
9. USE PROPER EXTENSION CORD. Make
sure your extension cord is in good condition. Conductor size should be in accordance with the chart below. The amperage
rating should be listed on the motor or tool
nameplate. An undersized cord will cause
a drop in line voltage resulting in loss of
power and overheating. Your extension
cord must also contain a ground wire and
plug pin. Always repair or replace extension cords if they become damaged.
Minimum Gauge for Extension Cords
10. WEAR PROPER APPAREL. Do not wear
loose clothing, gloves, neckties, rings,
bracelets, or other jewelry which may get
caught in moving parts. Non-slip footwear
is recommended. Wear protective hair covering to contain long hair.
11. ALWAYS USE SAFETY GLASSES. Also
use face or dust mask if cutting operation is
dusty. Everyday eyeglasses only have impact
resistant lenses, they are NOT safety glasses.
12. SECURE WORK.Use clamps or a vise to hold
work when practical. It’s safer than using your
hand and frees both hands to operate tool.
13. DO NOT OVERREACH. Keep proper foot-
ing and balance at all times.
14. MAINTAIN TOOLS WITH CARE. Keep
tools sharp and clean for best and safest
performance. Follow instructions for lubricating and changing accessories.
15. USE RECOMMENDED ACCESSORIES.
Consult the owner’s manual for recommended accessories. The use of improper
accessories may cause risk of injury.
LENGTH
AMP RATING 25ft 50ft 100ft
0-6 18 16 16
7-10 18 16 14
11-12 16 16 14
13-16 14 12 12
17-20 12 12 10
21-30 10 10 No
Safety Instructions For Power Tools
16. REDUCE THE RISK OF UNINTENTIONAL STARTING. On machines with mag-
netic contact starting switches there is a
risk of starting if the machine is bumped or
jarred. Always disconnect from power
source before adjusting or servicing. Make
sure switch is in OFF position before reconnecting.
17. MANY WOODWORKING TOOLS CAN
“KICKBACK” THE WORKPIECE toward
the operator if not handled properly. If you do
not understand what kickback is, or how to
prevent it, Do Not operate this machine.
18. CHECK DAMAGED PARTS. Before fur-
ther use of the tool, a guard or other part
that is damaged should be carefully
checked to determine that it will operate
properly and perform its intended function.
Check for alignment of moving parts, binding of moving parts, breakage of parts,
mounting, and any other conditions that
may affect its operation. A guard or other
part that is damaged should be properly
repaired or replaced.
19. NEVER LEAVE TOOL RUNNING UNATTENDED. TURN POWER OFF. Do not
leave tool until it comes to a complete stop.
20. NEVER OPERATE A MACHINE WHEN
TIRED, OR UNDER THE INFLUENCE OF
DRUGS OR ALCOHOL. Full mental alert-
ness is required at all times when running
a machine.
21. NEVER ALLOW UNSUPERVISED OR
INEXPERIENCED PERSONNEL TO
OPERATE THE MACHINE. Make sure
any instructions you give in regards to
machine operation are approved, correct,
safe, and clearly understood.
22. IF AT ANY TIME YOU ARE EXPERIENCING DIFFICULTIES performing the intend-
ed operation, stop using the machine!
Then contact our service department or
ask a qualified expert how the operation
should be performed.
-4- Ultimate Series Jointers
No list of safety guidelines can be complete.
Every shop environment is different. Always
consider safety first, as it applies to your
individual working conditions. Use this and
other machinery with caution and respect.
Failure to do so could result in serious personal injury, damage to equipment or poor
work results.
Additional Safety Instructions For Jointers
1. JOINTING SAFETY BEGINS with your
lumber. Inspect your stock carefully before
you feed it over the cutterhead. If you have
any doubts about the stability or structural
integrity of your stock, DO NOT JOINT IT!
2. MAINTAIN PROPER RELATIONSHIPS of
infeed and outfeed table surfaces and cutterhead knife path.
3. ALWAYS USE A PUSH BLOCK when
jointing. Never place your hands directly
over the cutterhead.
4. SUPPORT THE WORKPIECE adequately
at all times during operation, and maintain
control over the work at all times.
5. WHEN JOINTING, do not stand directly at
the end of either table. Position yourself
just to the side of the infeed table to protect
yourself from possible kickbacks.
6. NEVER MAKE JOINTING CUTS deeper
than
1
⁄8".
7. NEVER JOINT A BOARD that has loose
knots. All defects should be cut out of the
board before it is planed or jointed.
8. NEVER JOINT end grain.
9. JOINT WITH THE GRAIN. Jointing against
the grain is dangerous and could produce
chatter or excessive chip out , which could
lead to loss of control over the workpiece.
10. WITH THE EXCEPTION OF RABBETING,
all operations must be performed with the
guard in place. After rabbeting, be sure to
replace the guard.
11. NEVER BACK THE WORK toward the
infeed table. If a cut must be interrupted, lift
the workpiece clear of the cutterhead.
12. HABITS – GOOD AND BAD – are hard to
break. Develop good habits in your shop
and safety will become second-nature to
you.
13. “KICKBACK” is when the workpiece is
thrown off the jointer table by the force of
the cutterheads. Always use pushblocks
and safety glasses to reduce the likelihood
of injury from “kickback.” If you do not
understand what kickback is, or how it
occurs, Do Not operate this machine.
14. BE AWARE THAT CERTAIN WOODS
MAY CAUSE AN ALLERGIC REACTION
in people and animals, especially when
exposed to fine dust. Make sure you know
what type of wood dust you will be exposed
to and always wear an approved respirator.
Ultimate Series Jointers -5-
SECTION 2: CIRCUIT REQUIREMENTS
220V Operation
The Ultimate Series Jointers have a 3 H.P., 3450
R.P.M. motor which requires a 220V single-phase
circuit. The cord set enclosed does not have a
plug as the style of plug you require will depend
upon the type of service you currently have or
plan to install. The motor will safely draw about 15
amps at 220V under load. If you operate the
Ultimate Series Jointers on any circuit that is
already close to its capacity, it might blow a fuse
or trip a circuit breaker. However, if an unusual
load does not exist, and power failure still occurs,
have the circuit inspected by a qualified electrician.
Circuit Load
When operating at 220V, we recommend using a
NEMA-style 6-15 plug and outlet. See Figure 1.
You may also “hard-wire” the machine directly to
your panel, provided you place a disconnect
switch near the machine. Check the electrical
codes in your area for specifics on wiring requirements.
Under normal use, the motor draws approximately 15 amps at 220V. We recommend a 15 amp circuit breaker for 220V operation. This should be
satisfactory for normal use while providing
enough protection against circuit damage caused
by power surges. Always check to see if your current wires are capable of handling a 15 amp load.
If you are unsure, consult the advice of a qualified
electrician.
Figure 1. Typical 220V 3-prong plug and outlet.
-6- Ultimate Series Jointers
We do not recommend the use of extension cords
with 220V equipment. It is much better to arrange
the placement of your equipment and the installed
wiring to eliminate the need for extension cords.
Should it be necessary to use an extension make
sure the cord is rated Hard Service (grade S) or
better. Refer to the chart in Section 1: Safety
Instructions to determine the minimum gauge for
the extension cord. The extension cord must also
contain a ground wire and plug pin. Always repair
or replace extension cords when they become
worn or damaged.
We have covered some basic electrical
requirements for the safe operation of your
machine. These requirements are not necessarily comprehensive. You must be sure
that your particular electrical configuration
complies with local and state codes.
Ensure compliance by checking with your
local municipality or a licensed electrician.
Grounding Extension Cords
In the event of an electrical short, grounding provides electric current a path of least resistance to
reduce the risk of electrical shock. This tool is
equipped with an electric cord having an equipment-grounding conductor which must be properly connected to a grounding plug. The plug must
be plugged into a matching outlet that is properly
installed and grounded in accordance with all
local codes and ordinances.
Improper connections of the electrical-grounding
conductor can result in risk of electric shock. The
conductor with green or green and yellow striped
insulation is the electrical-grounding conductor. If
repair or replacement of the electric cord or plug
is necessary, do not connect the equipment
grounding conductor to a live terminal.
This equipment must be
grounded. Verify that any
existing electrical outlet
and circuit you intend to
plug into is actually
grounded. Under no circumstances should the
grounding pin from any
three-pronged plug be
removed. Serious injury
may occur.
Ultimate Series Jointers -7-
SECTION 3: INTRODUCTION
We are proud to offer the Ultimate Series Jointers.
These machines are part of a growing Grizzly
family of fine woodworking machinery. When
used according to the guidelines set forth in this
manual, you can expect years of trouble-free,
enjoyable operation and proof of Grizzly’s commitment to customer satisfaction.
The Ultimate Series Jointers all feature 3 H.P.
TEFC motors. The cutterhead knives are laminated high speed steel, resharpenable, and are
adjusted by means of jack screws, making blade
setting quick and easy. Spiral cutterhead models
feature indexed solid carbide cutters that can be
rotated through 4 different cutting surfaces before
needing to be changed. The infeed and outfeed
tables are precision ground cast iron and
adjustable by means of handwheels. The operator controls are conveniently mounted on a
pedestal above the tables. The Ultimate Series
Jointers incorporate cast iron stands and a dust
chute for easy connection to a dust collection system.
We are also pleased to provide this universal
manual covering all of the Ultimate Series
Jointers. It was written to guide you through
assembly, review safety considerations, and
cover general operating procedures. It represents
our effort to produce the best documentation possible. If you have any comments regarding this
manual, please write to us at the address below:
Grizzly Industrial, Inc.
C
/O Technical Documentation
P.O. Box 2069
Bellingham, WA 98227-2069
The specifications, drawings, and photographs
illustrated in this manual represent the Ultimate
Series Jointers as supplied when the manual was
prepared. However, owing to Grizzly’s policy of
continuous improvement, changes may be made
at any time with no obligation on the part of
Grizzly. Whenever possible, though, we send
manual updates to all owners of a particular tool
or machine. Should you receive one, we urge you
to insert the new information with the old and keep
it for reference.
Commentary
Read the manual before
assembly and operation. Become familiar
with the machine and its
operation before beginning any work. Serious
personal injury may
result if safety or operational information is not
understood or followed.
Most importantly, we stand behind our machines.
If you have any service questions or parts
requests, please call or write us at the location
listed below.
Grizzly Industrial, Inc.
1203 Lycoming Mall Circle
Muncy, PA 17756
Phone: (570) 546-9663
Fax: (800) 438-5901
E-Mail: techsupport@grizzly.com
Web Site: http://www.grizzly.com
-8- Ultimate Series Jointers
Ultimate Series Jointers
Terms and Definitions
G9859 G9860 G9861G9860ZX
Description
Table Size
Cutterhead Speed
Cutterhead
Motor
Fence Size
Weight
8 1⁄2" x 73 3⁄8"
5900 R.P.M.
4" Dia., 3 Knife
3 H.P./1 PH.
4
3
⁄4" x 39 1⁄4"
900 lbs.
12
1
⁄2" x 80"
5900 R.P.M.
4" Dia., 3 Knife
3 H.P./1 PH.
4
3
⁄4" x 39 1⁄4"
1080 lbs.
12
1
⁄2" x 80"
5900 R.P.M.
Spiral Cutterhead
3 H.P./1 PH.
4
3
⁄4" x 39 1⁄4"
1080 lbs.
14
1
⁄4" x 79 3⁄4"
5900 R.P.M.
4" Dia., 3 Knife
3 H.P./1 PH.
4
3
⁄4" x 39 3⁄8"
1210 lbs.
Infeed Table: The infeed table is the table where
the cutting operation begins. When facing the
front of the jointer, it is on the right hand side.
The wood travels right to left; from the infeed
table, across the cutterhead, and onto the outfeed table.
Outfeed Table: The outfeed table is the table
where the cutting operation ends. When facing
the front of the jointer, it is on the left hand side.
Cutterhead: The cutterhead is the cylindrical
assembly that holds each of the three jointer
knives. It spins on a horizontal axis between
the infeed and outfeed table, and is covered by
the cutterhead guard when the jointer is not in
use.
Fence: The jointer fence is the adjustable cast
iron surface that the wood stock runs along
when jointing and surface planing. The fence is
adjustable from 45° to 90° to the infeed and
outfeed tables.
Adjustment Handwheels: Controls the height of
the infeed and outfeed tables.
Table Lock Handles: The threaded handles that
must be loosened before the height of the
tables can be adjusted. They are then tightened after the height is properly set.
Rabbet Cut: A rabbet cut is a groove cut along
the long edge of the wood stock. This cut is
typically used in carcass construction. The cutterhead guard must be removed for this operation so great care is needed for safe operation.
Surface Planing: Surface planing is running the
face of the wood stock over the jointer. This
provides one flat side that is ready to be run
through a dedicated planing machine.
Edge Jointing: Edge jointing is running the long
edge of the wood stock over the jointer. This
provides one flat edge that is ready to be run
against the table saw rip fence or ready to be
edge glued.
Cutterhead Guard: The metal guard that covers
the cutterhead when wood stock is not passing
over the jointer.
Ultimate Series Jointers -9-
Unpacking Piece Inventory
NOTICE
A full parts list and breakdown can be found
toward the end of this manual. For easier
assembly, or to identify specific parts,
please refer to the detailed illustrations at
the end of the manual.
Ultimate Series Jointers consist of:
• Jointer Assembly (Not Shown)
• Fence Assembly
• Cutterhead Guard
• Push Blocks (2)
• Fence Base Support
• Tool Bag
- 8, 6, 5, 4, 3mm Allen
®
Wrenches
- 11/13mm Open End Wrench
- Knife Setting Gauge
The Ultimate Series Jointers are shipped from the
manufacturer in a carefully packed carton. If you
discover the machine is damaged after you’ve
signed for delivery, immediately call Customer
Service for advice.
When you are completely satisfied with the condition of your shipment, you should inventory its
parts.
Figure 2. Ultimate Series Jointer layout.
The Ultimate Series
Jointers are heavy
machines. DO NOT
over-exert yourself
while unpacking or
moving your machine
– you will need assistance and power
equipment. Serious
personal injury may
occur if safe moving
methods are not followed.
Make sure floor structure is capable of supporting the combined
weight of the machine
parts and people.
-10- Ultimate Series Jointers
Site Considerations
FLOOR LOAD
Your Ultimate Series Jointer represents a large
weight load in a medium footprint. Most commercial or home shop floors should be sufficient to
carry the weight. If you question the strength of
your floor, you may wish to check with an architect
or structural engineer in your area to make certain
it can handle the load.
WORKING CLEARANCES
Working clearances can be thought of as the distances between machines and obstacles that
allow safe operation of every machine without limitation. Consider existing and anticipated machine
needs, size of material to be processed through
each machine, and space for auxiliary stands
and/or work tables. Also consider the relative
position of each machine to one another for efficient material handling. Be sure to allow yourself
sufficient room to safely run your machines in any
foreseeable operation.
LIGHTING AND OUTLETS
Lighting should be bright enough to eliminate
shadow and prevent eye strain. Electrical circuits
should be dedicated or large enough to handle
combined motor amp loads. Outlets should be
located near each machine so power or extension
cords are not obstructing high-traffic areas. Be
sure to observe local electrical codes for proper
installation of new lighting, outlets, or circuits.
Clean Up
The unpainted surfaces are coated with a waxy oil
to protect it from corrosion during shipment.
Remove this protective coating with a solvent
cleaner or citrus-based degreaser such as
Grizzly’s G7895 Degreaser. Avoid chlorine-based
solvents as they may damage painted surfaces
should they come in contact. Always follow the
usage instructions on the product you choose for
clean up.
Make your shop “child
safe.” Ensure that your
workplace is inaccessible
to youngsters by closing
and locking all entrances
when you are away. Never
allow visitors in your shop
when assembling, adjusting or operating equipment.
Many of the solvents
commonly used to clean
machinery can be toxic
when inhaled or ingested. Always work in wellventilated areas far from
potential ignition sources
when dealing with solvents. Use care when disposing of waste rags and
towels to be sure they do
not create fire or environmental hazards.
Do not smoke while using
solvents. A risk of explosion or fire exists and may
result in serious personal
injury.
Do not use gasoline or
other petroleum-based
solvents. They have low
flash points which make
them extremely flammable. A risk of explosion
and burning exists if
these products are
used. Serious personal
injury may occur if this
warning is ignored.
Ultimate Series Jointers -11-
SECTION 4: ASSEMBLY
Beginning Assembly
Most of your Ultimate Series Jointer has been
assembled at the factory, but some parts must be
assembled or installed after delivery. We have
organized the assembly process into steps.
Please follow along in the order presented here.
TOOLS REQUIRED: You will need a high quality
square, 45° angle gauge, a long straightedge,
11/13mm open end wrench, and a 8, 6, 5, 4 and
3mm Allen
®
wrench.
Disconnect power to the
machine when performing any maintenance,
assembly or adjustments. Failure to do this
may result in serious
personal injury.
Keep loose clothing
rolled up and out of the
way of machinery and
keep hair pulled back.
Wear safety glasses
during the entire assembly process. Failure to
comply may result in
serious personal injury.
Fence
DO NOT slide the fence across the outfeed
table. Scratching will result.
NOTICE
To install the fence assembly:
1. Using (2) M12-1.75 x 35 cap screws, (2) M12
washers, and (2)
5
⁄
8" I.D. x 3mm thick x 38mm
O.D. special washers, attach the fence base
support to the jointer assembly as shown in
Figure 3. Make sure the special washers are
between the fence base support and the jointer assembly. The 2 washers go between the
cap screw head and the jointer assembly.
Tighten securely.
2. Make sure the 10 x 8 x 260mm key is fitted
into the key way on the fence base support as
shown in Figure 4.
The fence assembly is
a heavy part. Seek
assistance when lifting
it onto the fence base
support.
Figure 3. Attach fence base support to jointer
assembly.
Some metal parts may
have sharp edges on
them after they are
formed. Please examine
the edges of all metal
parts before handling
them. Failure to do so
could result in injury.
Fence Base Support
!
-12- Ultimate Series Jointers
Cutterhead Guard
The cutterhead guard spring tension comes preset from the factory. To install the cutterhead
guard:
1. Loosen the black plastic knob shown in
Figure 6.
2. Slide the cutterhead assembly post into the
slot shown in Figure 6.
3. Tighten the black plastic knob that was loos-
ened in Step 1.
4. When rotated, make sure the cutterhead
guard rotates back over the cutterhead
assembly.
Figure 4. Properly installed key.
Figure 5. Fence base lock knob attachment.
Figure 6a. Attaching cutterhead guard.
3. Carefully lift the fence assembly onto the
fence base support. Make sure that the key is
fully seated into the key way. Avoid letting the
fence slide across the jointer tables.
4. Slide the lock handle shaft through the flat
washer and into the slot on the top of the
fence assembly base. Thread the slide piece
onto the end of the lock knob shaft as shown
in Figure 5.
5. Thread the fence adjustment handle into the
tapped hole on the top edge of the fence.
6. With the lock knob loose, the fence assembly
should slide smoothly across the key way.
Avoid letting the fence drag across the tables.
Installed Key
Ultimate Series Jointers -13-
Pedestal Switch
Your jointer comes with a pedestal mounted magnetic switch for safety and convenience. Simply
bolt the pedestal to the four mounting holes on the
back side of the stand with (4) M10-1.5 x 25 cap
screws and (4) M10 flat washers as shown in
Figure 7A & 7B.
Figure 7A. Mounting the pedestal switch.
Figure 7B. Mounted pedestal switch.
-14-
Ultimate Series Jointers
SECTION 5: ADJUSTMENTS
Note: The Model G9860ZX has a spiral cutter-
head in place of the knife cutterhead. Adjustment
will be discussed in the next section.
The knives of your jointer must be periodically
replaced or adjusted. Adjustments should be as
precise as possible with tolerances within .002".003" to prolong the sharpness of the knife edges.
Improperly adjusted knives can unbalance the
cutterhead and shorten bearing life, as well as
produce substandard jointing or planing results.
1. Unplug the jointer! Remove the cutterhead
guard to expose the top of the cutterhead.
2. Carefully turn the cutterhead (using the pul-
ley) until the first knife is at top dead center.
Engage the brake rod to secure the cutterhead into a stationary position as shown in
Figure 8.
3. Using the knife setting gauge, check the knife
height. The jig should sit solidly with the feet
resting on the outfeed table and the knife
edge as shown in Figure 9. If the knife is
adjusted properly, the knife setting gauge
should rest flush across the outfeed table
and onto the top edge of the knife. If the knife
does not make contact, or if the knife causes
the adjusters legs to not seat flush on the outfeed table, the knives need to be adjusted.
KnivesGeneral
Always lock the table
with the table lock
before using the jointer.
If this step is not
observed, the table
could slide down while
the jointer is operating.
Serious personal injury
may occur.
Jointer knives are extremely sharp. Never
grab the cutterhead directly to rotate it.
Always use the drive pulley. Always be sure
the jointer is disconnected from its power
source before you make any adjustments.
Serious personal injury may occur.
Disconnect power to the
machine when performing any maintenance,
assembly or adjustments. Failure to do this
may result in serious
personal injury.
Keep loose clothing
rolled up and out of the
way of machinery and
keep hair pulled back.
Wear safety glasses
during the entire adjustment process. Failure
to comply may result in
serious personal injury.
The Model G9953 is supplied with a 4 knife
cutterhead, while the Models G9859/60/61
have 3 knife cutterheads.
NOTICE
Table Lock
!
Ultimate Series Jointers -15-
Knife Setting
Gauge
Gib
Gib Bolt
Jack Screw
Knife
Outfeed Table
4. Adjust the screws below each end of the
knife until both feet of the gauge rest flush
and evenly on the outfeed table and the knife
edge is just touching the bottom of the gauge.
Securely tighten each gib bolt. The gauge will
set the knives at a uniform protrusion above
the cutterhead. The knife height should vary
no more than .002"-.003" across the length of
the cutterhead. A dial indicator can be used
to check variation in thousandths of an inch;
however, the standard knife setting gauge is
satisfactory for reasonably accurate knife setting tasks.
5. Repeat the same procedure on the remaining
knives.
The knives are locked into the cutterhead with
wedge-type gibs and gib bolts. Jack screws under
the knives allow fine tuning to help in the setting
process. To re-align the knives:
1. Unplug the jointer!
2. Loosen the gib bolts until the knife is loose in
the slot. The gib bolts turn clockwise to
loosen and counterclockwise to tighten
(when facing the head of the bolt). See
Figures 10 and 11.
3. Place the knife setting gauge across the knife
edge and the outfeed table as described previously.
Figure 9 shows the setting of the knives with the
knife setting gauge.
Figure 10. Parts of the cutterhead.
Figure 11. Tightening the gib bolts.
Figure 8. Engaging the brake rod.
Knife Edge At
Highest Point
of Rotation
Brake Rod
Tighten
Loosen
Knife
Gib Bolt
Gib
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